TURN-key

Coordination between control and field instrument, drive is a big challenge in an automation project. Generally, multiple suppliers and vendors with different quality level get involve in an automation project because not only the budget and quality of field devices and their conformity with the customer requirement but also vendor’s local support and local inventory affect on vendor selection.

RETROFIT LARGE CONTROL SYSTEM IN MULTIPLE PHASES

In a control system modernization project, amount of risk for returning to last production in preschedule time, necessity for plant downtime and budget of migration plan against advantage can be gained by new control system conduct customers to choose between these modernizations scenarios:
1-HMI 
2-Controller and HMI 
3-Complete change

DCS MIGRATION BY HOT CUTOVER

Zero plant down time is an aim of any DCS migration plan. Depends on type of changes that are considered in a DCS modernization plan there are multiple solution and method in the market. A hot cutover is a solution for moving loops to new control system in online process condition. Utilizing hot cutover plan and tools can prevent plant downtime during migration process. 

CONTROL SYSTEM UPGRADE BY ZERO PLANT DOWNTIME

The new modern control system advantages in improving production throughput and increasing plant safety against high maintenance cost of legacy control system may direct customers to a complete replacement plan, but replacing whole the control system by a new one aside from higher cost is not always the best solution to gain those advantages and dissolve the maintenance issues. 

CHANGE VENDOR TECHNOLOGY IN A DCS MIGRATION

When cost of maintaining legacy control system and risks of plant downtime increased, desire for resolving old DCS issues and gain advantage of modern control system put the customer at two-way selection; migrate to a new DCS by staying on vendor technology or change the technology.

ADD VALUES TO OLD GAS TURBO MACHINES BY RETROFIT

The high budget of gas turbo generators is an obstacle for investing on them at industries with large amount of electricity consumption that desire to have in-house steady low cost source of power. Investment in used robust gas turbo machines is a cost effective solution for those factories that wants to have their own in-house power station.

TURN KEY REVAMPING

7209 was a retrofit project in a gas condensate separation plant in upstream of a large petrochemical factory with million dollar revenue in a month. Any shutdown cost for customer a lot but inefficient operating among system failures increasing, part unavailability, and reduced support caused frequently plant downtime and risk of safety incident and loss revenue directed the customer to a retrofit solution.

UPGRADE TO ABB 800xA

Project 7129 was about upgrading DCS, ESD (Emergency shutdown) and F&G (Fire and Gas detection System) of an oil offshore platform with zero plant downtime. Existing control system in the platform includes, three Redundant Set of ABB Advant AC450 in DCS and two sets of Dual Safegaurd in ESD and F&G system and five ADVA command operator consoles.

STEAM TURBINE GOVERNING

As part of a big petrochemical revamping project we retrofitted control system of steam turbines from Ellliot-Ebara at heart of a process plant. Additional to high cost of maintenance and insufficient operation, the old hydraulic governor system of steam turbine was raising problems during operation and caused many unexpected plant shutdown.

SIEMENS PROCESS CONTROL SYSTEM

The project code 7304 was about complete retrofit of copper concentration plant by changing the technology. The customer had ABB Advant Colibri system and increasing risk of system failure, cost of maintenance and obsoleted system function lead them to a modernization project. We changed their system Technology from ABB to Siemens. PCS7 is modern cost effective solution for process controls with scalable architecture. 

SIEMENS FOR WATER TREATMENT

Due to revamping of a Petroleum refinery and by increasing refining capacity the customer constructed a new water treatment unit to achieve effluent water quality in order to reuse the water in the processing plant as make up for cooling towers and for reusing in demin unit.

RETROFITING GAS TURBINE

Turbine retrofit need deep knowledge in automation and machine control, we are experienced in retrofitting different type of gas turbine compressor and generators like project 7108.  
The project 7108 was about retrofit a power plant in a zinc factory by changing control system technology.

LARGE DISTRIBUTED CONTROL SYSTEM

Project code 7508 was about retrofitting of a large control system in a steel complex. The customer intended to upgrade obsoleted control system of multiple factories in the steel complex due to increasing in cost of maintenance and risk of system failure.

HONEYWELL TDC3000 MIGRATION TO EXPERION PKS-OIL REFINERY

Our customer in petroleum refinery intended to upgrade their Honeywell TDC 3000 legacy control system. By considering to budget and plant downtime, we put three upgrading scenarios on the table for the customer, Upgrade only HMI, Upgrade HMI and replace controller, complete replacement and the customer chose migration  to Experion PKS by upgrading HMI and replacing the controllers.

HIMA BOILER MANGEMENT SYSTEM

The boilers are the most fundamental systems in refining process and despite simple logic often used in other safety applications and mostly they are based on a cause and effect table, the logic in boiler management systems are more complicated and need high automation programming skills.

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